Egg carton



E. L. MCKEE Jan.`l3, 1942.

' EGG CARTON v Filed April 29, 195s 2 Sheets-Sheet l EdwardLMSm-e E, L. MCKEE Jan. 13, 1942.

EGG CARTON Filed April 29k, 193s 2 Sheets-Sheet 2 i f i? Patented Jan. 13, 1942 Unirse srr 'l OFFICE 10 Claims.

This invention relates to improvements in cartons, being especially adapted for packaging eggs, although it is conceivably usable for packaging other articles of fragile nature. Confining the adaptation oi the carton tothe packaging of eggs, it is commonly known in this respect that known cartons are far from being satisfactory largely from either of two standpoints, first, that the eggs are insecurely packed, second, that they v With this preamble in mind, the objects of the invention are as follow:

First, to provide an egg carton of such construction that when eggs are packed therein they are Virtually held in suspension, being separately spaced and cushioned and thereby guarded to a greater extent than usual against breakage.

Second, to provide an egg wherein the eggs are cradled in arches oi paper or the like, practically floating the eggs while stored in the carton.

Third, to provide a carton wherein the eggs are held in leaning positions, enabling the packing of longer and thicker eggs in the available space than would ordinarily be possible.

Fourth, to provide a carton wherein resilient arches are employed to support the eggs, these same arches permitting a suicient degree of movement in the pockets formed by the arches, so that they may adapt themselves to the best possible positions.

Fifth, to provide for setting the eggs in the adjacent rows at a pitch toward the medial line of the carton, thereby automatically directing the force which tends to unfold the arches downwards toward said medial line, thereby to hold the form of the egg holding device when put into the iilling tray.

Sixth, to provide an egg carton wherein an arch is primarily used for the support and suspension of an egg, said arch being advantageous both from the standpoint of putting in and taking out the eggs, both acts being facilitated.

Seventh, to embody the arch construction of egg holding device to the known and more common types of boxes or cartons, the latter serving the purpose, to a certain extent of the lling tray mentioned above.

Eighth, to practice a novel method of packing eggs, one step of which involves the use of the fillingtray for temporarily holding the egg holding device.

Other objects and advantages will appear in the following specication, reference being had to the accompanying drawings, in which:

Figure l is a perspective view of the main form of the improved carton, a portion being broken away to disclose'the internal structure.

` Figure 2 is a longitudinal section taken substantially on the line 2-2 of Fig.'1.

Figure 3 is a plan view of the egg holding device.

Figure 4 is a cross section on the line 4--4 of Fig. 2.

Figure 5 is a plan View of the sheet from which the preferred type of egg holding device is formed.

Figure 6 is a cross section illustrating the emplacement of the egg holding device in the assembling tray.

Figure '7 is a plan view of the wrapper blank.

Figure 8 is a miniature perspective view of the assembling tray.

Figure 9 is a plan View of the sheet from which the stabilizing device is formed.

Figure l0 is a fractional plan View of the second type of sheet from which an egg holding device is formed.

Figure 11 is a fractional plan view of a third type of sheet from which an egg holding device is formed.

Figure l2 is a cross section of a modiiied type.

of carton wherein a known box is combined with the improved egg holding device.

Figure 13 is a perspective view of a dividing strip used in conjunction with the modied carton.

In carrying out the invention provision is` made of' an egg cartonl I which is intended to be constructed in accordance with either of two mod'- ifications. Reference is rst made to Figs. l to 9 which illustrate the rst type. In respect to this type the carton consists of three principal elements, namely, an egg holding device 2 (Fig. 3),y a stabilizing device 3 (Fig. 9) and an outer shell or wrapper 4 (Fig. 7). The eggv holdingdevice 2 originally consists of a sheet 5 (Fig. 5*) of inherently unstable material.. Customarily it will consist of paper of a suiciently heavy grade, but it maycomprise some other limp. and equally suitable material.

This sheet is medially scored at 6 (Fig. 5), thereby dividing the sheet into a pair of wings or sections 1, 8. In the approximate center of the sheet parallel slits 9 are cut in. These slits extend transversely of the sheet and crosswise of the direction of the medial score 6, interrupting the latter, as plainly shown in Fig. 5. In other Words, the medial score 6 does not cross that portion of the sheet between the slits 9.

Said slits are connected by parallel scores I0, II, the former constituting a pair which connect the terminals of the slits, the latter being oicentered from the score 6. In fact the slits 3 may also be off-centered, although this is not always essential. 'I'he result of the slitting lo, II, especialll7 of the off-centering of the slit I I, is the nucleus of a shoulder I2. The ultimate form of this shoulder is shown in Fig. 6.

The sections 1 and 8 have pocket patterns I3 arranged in rows. Inasmuch as all of the pocket patterns are alike the description of one will be sufficient. The rst and preferred type of pocket pattern I3 (Fig. 5) comprises a p-air of inwardly directed curved scores I4, I5. The score I4 is approximately a half circle. The score I5 is a much less part of a circle. A transverse slit I6 comprises the common base line of the terminals of both scores I4, I5. A second slit I1 within the confines of the score I4 constitutes a chord of the half circular score. The result of this slitting is the projection of plural lips I8 with an intermediate strap I9.

The lips and straps provide a pocket formation in which an egg will be suspended from the respective section I3 or I4 when the sheet 5 is constricted to round the sections 1, 8 into a pair of arches from the crowns of which the pockets will hang by suspension. Inasmuch as this phase of the invention has been mentioned, attention is .directed to Fig. 6 for the construction involved.

In Fig. 6 the arches are designated 2D. These arches are identical with the sections 1 and 8, but now being disclosed in their final form. In this form the lips I8 serve the important purpose, additionally to providing parts of pockets for the eggs, of trusses or bridges under the arches 20. They make the curves of the arches the strongest parts so that the arches will stand up under considerable strain, due to the weight of the eggs. This construction also permits setting the eggs close together because the lips I8 depend from the scores I4, I5, and the latter can readily be placed quite close together, in fact they touch as plainly shown. The medial score 6 constitutes the creasing line, the portions 2I of the sheet adjacent to the medial score constituting a central pier. The marginal portions 22 of the sheet (Fig. 5) becolne outside piers, similarly designated 22 in Fig. 6. In practice the portions of the pier 2| are quite close, placing the arches in contiguous relationship. The shoulder I2 is folded upon its creases, then assuming its ulti- -mate position in which it stands ready to be interlocked with the stabilizing device 3 and wrap- Per 4.

Referring again to Fig. 5 it is to be noted that the distances 23 between the adjacent crests of curved scores I4 and medial score 6 are less than the distances 24 between the remote crests of said scores and the edges of the marginal portions 22.`

'I'his arrangement places the center lines 25 of the pocket rows I3 off-center in the sections 1, 8, said lines being slightly closer to the medial score 6 then to the remote longitudinal edges.

The purpose and result of this off-centering of the pocket rows I3 is to cant the arches 20 (Fig. 6) toward the center of the egg holding device. This canting occurs because of the outside piers 22 being slightly taller than the central pier 2I. The pockets I3 are set slightly oi the crown of the arches toward the medial line of the egg holding device, and by this arrangement the lines of force in the arches tending to unfold them, are directed lower toward said medial line, automatically holding the egg holding device in place when it is fitted into the assembling tray (Fig. 8) in the manner later explained.

In further reference to Fig. 5 it is to be noted that half of the pockets I3 are directed one way, the other half being .directed the other way. If a line were drawn across the transverse center of the sheet 5 it would constitute a central division toward which the two sets of pockets are directed. When the eggs are emplaced in the pockets, arranged as just stated, the two half sets of eggs lean from each end of the device toward its middle. This is an advantage in that a firmer grip is gotten on the four eggs at the ends of the arches 20, preventing them from working out of the carton, (see Fig. 2).

Reference is now made to Fig. 9. The stabilizing ydevice 3 here shown comprises a sheet 26 of paper of a suitable grade or of some equivalent limp material, which is medially scored at 21 to divide the sheet into sections 28, 28. Said sheet is further scored at in parallelism to the score 21 and from there out the sections 28, 29 are slitted at 3| to produce flaps 32 which will be in covering relationship to the eggs contained by the pockets I3. The slits 3I are in line with the division points between the egg pockets I3 (Fig. 5). when the carton is assembled. A small section of the sheet 2E is cut out in its approximate center at 33 to form a notch when the sheet is folded. This notch will t over the shoulder I2 in the assemblage.

Reference is next made to the wrapper 4 (Fig. 7). This is the nal shell that completes the carton assemblage. It comprises a sheet 34 of paper, usually fairly heavy cardboard, or some acceptable substitute, which has parallel scores 35 which define a bottom 36 and aps 31. The bottom is reinforced in the transverse direction by a plurality of ribs 38 which are simply embossed into the material. These ribs form supports for the carton and absorb shocks due to the contact of the bottom 36 with a solid surface, such as a table.

Notches 39 are cut into the remote margins of the respective aps 31. These margins are intended to correlate with the shoulder I2 of the egg holding device 2 (Fig. 6) and with the notch 33 of the stabilizing device 3 in the iinal assemblage.

In the latter respect attention is now directed to the manner in which the assemblage is made. This involves a novel method. Use is made of an assembling tray 40 (Fig. 8). This tray is made of metal and it is anged at 4I along its longitudinal edges. These flanges have a slight inward pitch (Fig. 6). The tray is approximately as Wide as the resulting carton, and it is sufciently longer than the carton to enable withdrawing the tray when the carton assemblage is completed.

Numbers of at wrapper sheets 34 are placed on the table directly in front of the operator. Equal numbers of the sheets 2 and 3 (Figs. 5 and 9) are also placed on the table within convenient reach. The tray 40 (Fig. 8) is placed upon the bottom sectionv 36 of the wrapper 4 (Fig. 7)'.

One ofthe sheets 5- (VF-'ig'. 5-) is now placed in the trayl 40 by bending the marginal portions 22 down and creasing thev sheet along itsY medial score 8. The latter is done by pressing the fingers along said score on each side of what presently will become the shoulder I2. The resultoi these manipulations is toV transversely bow the sections 1, 8 into two parallel arches.

Because of the scoring and slitting of the pocket patterns IIS", supplemented byv some pressing and flexing of the lips and straps thereof, the pockets automatically form themselves by inward displacement from the crowns of the arches, stopping short, however, fromv the bottom 40 of the trayl so as to remain in suspension, as plainly designated in` Fig. 6'.

Inasmuch as said pockets are set slightly oli the crowns of the two arches andv toward the medial line of the holding device 2, the latter is automatically held in the tray and against any tendency of springing up again in the center. The shoulder I2 now automatically forms itself because of the eccentricity or oli-centering of the score II. The shoulder can ex either upwardly (Fig. 6) or downwardly. The pockets I3 are now filled with eggs, whereupon the stabilizing device 3 is brought into play.

One of the sheets 26 of the latter (Fig. 9) is folded along its medial line 2'I and inserted in the space (Fig. 6.) between the two arches 20. The notch resulting from the cutout 3'3` is engaged with the shoulder I2 of the holding device 2. The flaps 32 assume a more or less covering relationship to the eggs.

The aps 3l of the wrapper 4 (Fig. 7). are now bent into arches, the creasing being done at the scores 35 along the bottom edges of the tray 48, the free ends of the iiaps being tucked downwardly and inwardly between the upstanding parts of the stabilizing device 3 (Fig. 4). The notches 39 engage the shoulder I2 of the holding device 2. The shoulder I2 is interlocked with the stabilizing device 3 and wrapper 4 in a sense. Said shoulder prevents endwise movement of these parts in respect. to the holding device.

The previously mentioned aps 32 of the stabilizing device 3 are pressed down by the arches of the wrapper 4, but they do not take the same curvature (Fig. 4) because of the specific location of what might be called the hinge-scores 30. As already stated, the iiaps 32 are held in covering relationship to the eggs, stabilizing the latter in their respective pockets.

The iinal act is to secure all parts of the carton by attaching securing means 42 to the wrapper 4 (Fig. l). This may comprise either gummed paper as indicated, or ordinary twine. The car.- ton is open-ended, and the tray 40 is now pulled out and placed upon the bottom 36 of the wrapper 4 next lowest.

Reference is next made to the modication of the carton in Figs. 12 and 13. The carton is generally designated Ia and such parts as are identical with those already described have the same reference numerals supplemented with the exponent letter a. An ordinary egg box is designated 43. This has the customary bottom 44,'

sides 45, and anged lid 46. The box 43 acts in the capacity of the assembling tray 40. The egg holding device 2a is folded and inserted in the box 43 in the precise manner described in conjunction with the tray 40.

The eggs are packed in the resulting pockets I3a. but. in lieuA ci the stabilizingI device; 3 as shown in- 9, use, is: madev of a centering division: stripy 4.1' (Fig: 13).'. comprises fairly heavy cardboard' and it isf stood in the place between the. arches 20a. (Fig. 12).". When. the. lid,

is new closed it presses: down on the top. edge of the stripI 4l insuring: the keeping in place ofv the egg holding device.

The latter still has; the shoulder I2a', but, in this particular assemblage the shoulder does not have the same function as it: did in. relationship to the stabilizing device. 3, and: wrapper" 4f. Al.- though'the. strip 41 constitutesl ai. stabilizing de.- vi'ce in the. sense of holding the device. Zai down, yet there. is no opportunity ofl its preventing lon,- gitudinal movement of the egg holding device because. the ends of' the box 43 do that. lRather than to manufacture a separate type. of sheet forthe purpose of the egg holding device in. Fig.

f 122, the. strip 4;'I is notched at: 4.8A so.- as to clear thek shoulder'l I2a'.

At this point attention is again directed to Fig. 5. The corners of the sections T, 8. are. trimmed at. 49.'. This trimming does not. perform a. function in Vthefiirst. form of the. carton, butwhen the sheet 5 is used in connection with the egg box 43 the trimmed corners 49 facilitate. the insertion oi thev holding device into the box, the. sides of which are,y generally fairly deep.

Reference is next made to Figs. l0: and 11 which disclose second and third types of sheets from which. egg holdingl devices lare formed. Those parts which are identical with Fig. 5 are designated by corresponding numerals; without further specic description. The distinctions. are as follow: In Fig. 10 the pocket; patterns, I3 are formed by curved scores 50 of even lengths. This produces the pointed ovals. shown. A single transverse.- slit. 5I hasl its termina-ls aitv the. approximate points of the respective oval. This particular configuration will produce a. fairly shallow pocket which is suitable forv small eggs.

In Fig. 11 the. curved scores. 52` are. of equal lengths as in Fig. 10, but the resulting pointed oval is cut by a plurality of slits 53. The present showing is that of three slits. The central and longest'I one meets the points of the oval, the shorter ones being more nearly identified as chords of the respective Apart-circles.

It is thought perfectly apparent that any type of egg. holding device herein disclosed provides suspended pockets in which the eggs areV cradled, when the sheet of the` respective holding device is bent into form. The eggs are all separately spaced and practically oat in mid air because of the resiliency of the arches'z and the character of the paper from which they are formed.

Another and nal advantage of the carton is that a very large surface of each egg exposed to View when the securing means 42' is broken and the wrapper 4i is removed. Consequently each egg may be grasped below its bulge for safe and easy removal.

In conclusion it is desired to lay stress upon the strong arch construction of the wrapper 4. This wrapper or outer shell aords a high degree of protection to the packaged articles from outside forces or blows, largely because of its arch construction. It is known from wide experience that a strong wrapper or outer shell is necessary to protect the articles in the carton during shipment and handling, this being especially true when the articles comprise eggs.

I claim:

l. A carton comprising a pair of longitudinally connected and'contiguous arches having their longitudinal marginal edges on a common plane, creases and slits crosswise of the arches forming pockets suspended from the arches to a depth falling short of said common plane, and a wrapper bottoming the arches and therefore occupying said common plane, said Wrapper being superimposed on the remote sides of the arches and having its longitudinal edges tucked in between the arches.

2. A carton comp-rising a medially creased article holding device, the resulting lateral sections being transversely slitted and being curvedly scored adjacently to the slits, the extremities of the slits and curved scores being closer to the medial crease than to the longitudinal edges of the sections, and a wrapper confining the article holding device in a double and parallel arched formation of the sections, the arches displacing the slotted portions to define suspended pockets at the curved scores, said pockets being pitched toward the division between the arches.

3. A carton article holding device consisting of a sheet medially scored to provide lateral sections, each of the lateral sections having plural pocket patterns comprising inwardly curved scores of different lengths, a transverse slit being the common base line of the terminals of both scores, and a second slit constituting a chord of the largest curved score.

4. A carton article holding device consisting of a sheet medially scored to provide lateral sections, each of the lateral sections having plural pocket patterns comprising inwardly curved scores of different lengths, a transverse slit being the common base line of the terminals of both scores, a second slit constituting a chord of the largest curved score, and a shoulder in the approximate center of the sheet, consisting'of a pair of slits crossing the direction of the medial crease, said slits being joined by plural scores and said medial score stopping short of the cross slits.

`5. An egg holding device comprising a sheet having a longitudinal series of pocket patterns, each pocket pattern consisting of reversely related curved scores connected by cross slits defining lips at the sides of each. pocket pattern, said sheet being bowed into an upright arch formation, disposing said lips downwardly in respect to each pocket and crosswise of the arch, respectively to cradle an egg and to form trusses for the arch.

6. An egg holding device comprising a sheet having a longitudinal series of pocket patterns, each pocket pattern consisting of reversely related curved scores being impressed into the sheet back to back in touching relationship to provide a close spacing of the resulting egg pockets, said scores being connected by cross slits defining lips extending crosswise of the pocket series Vand at the sides of each pattern, said sheet being bowed into an Vupright arch formation, disposing said lips curvedly downward into each pocket crosswise of the arch to strengthen the crown of the arch and both support and grip the eggs.

7. A carton comprising a single sheet, pocket formations in a row along said sheet to cradle articles therein, each pocket formation consisting of at least one straight transverse slit and confronting curvilinear scores having their terminals at said slit and defining chordal lips, and means to sustain the sheet in arch form crosswise of the pocket row, said chordal lips constituting cradles which are concave because of the adjustment of the curvilinear scores to the arch of the sheet and being suspended from the arch because of said scores bridging the crown thereof.

8. A carton comprising a single sheet, oppositely creased curves in closely spaced positions in a row and slitted transversely of the row between the terminals of the creases to provide pocket places, and a wrapper confining said sheet in a `transversely arched position, converting those portions of said sheet outlined by the creases and slits into pockets curved oppositely to the crowns of the arches and suspending the said pockets clear of a bottom plane common to the straight edges of the sheet.

9. A carton comprising an inherently unstable article holding device adapted to take the form of an inverted U-shape to define an arch, a pocket formation embodied in said device along the crown line of the arch, a wrapper in which said holding device is emplaced to constrict said device into said arch-formation, said pocket formation consisting of oppositely disposed curved scores and slits in chordal relationship to each curved score to form pockets in the article-holding device crosswise of the crown, and means interengaging the wrapper with the article holding device.

10. An egg holding device comprising a sheet having a medial crease anda longitudinal series of pocket patterns in each of a pair of sections segregated by said crease, each pocket pattern consisting of reversely related curved scores being impressed into the sheet back to back in touching relationship to provide a close spacing of the resulting egg pockets, said scores being connected by cross slits defining lips extending crosswise of the pocket series and at the sides of each pattern, the contiguous crests of said curved scores being spaced more closely to the medial crease than the remote crests of said scores are spaced from the side margins of said sections, said sheet being bowed. int'o an upright arch formation, disposing said lips curvedly downward into each pocket crosswise of the arch but in inwardly canted relationship to the longitudinal center of said device.

EDWARD L. McKEE. 

